Hello all. I am in the process of replacing a few windows. I ended up getting simonton daylight max to replace aluminum windows. It seems that the original frame was deep so after I inserted the window, there was only about 3/4" depth remaining from the edge of the original frame to the edge of the new window (image 1).

Is it OK if I screwed the vinyl frame through the original aluminum frame? I am not sure if that is best practice. There were no premade drill holes so I had to drill my own using a countersink.

Also some of the windows have about 1/2" gaps remaining as shown in image2. Should I put insulation inside the aluminum frame as well the outside of the frame? Or should insulation only go on the outside of the frame flush up to the vinyl window? I am not sure what the "best practice" is for insulation.

Thanks everyone!

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File comment: large gap between vinyl window and old aluminum frameimage2.jpg [17.1 KiB]
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Oops! Sorry about that. I hope this picture helps. The arrow I drew (yellow) is about 1/2" long. With that small amount of working space where would I place the screw holes in the window? Currently I drilled the screws through the current aluminum frame. Is that OK to do?

And regarding the gap you see in the picture between the window and aluminum frame, do I put insulation in the gaps and fill in the space between the flange and frame? Or do I only apply it in the area where the blue arrow is, that is outside the aluminum frame?

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